FIELD OF THE INVENTION
[0001] The present invention falls within the field of inspection of iron and steel products.
More specifically, the invention falls within the field of detection and reading,
both hot and cold, of printed elements on iron and steel products hidden by residue.
BACKGROUND OF THE INVENTION
[0002] One of the most complex problems to solve in the world of steel and iron, both for
tracking and controlling defects in pieces, is that due to the thermal treatments
on the surface of the product or to other circumstances, scales or other residues
appear on the surface of the product which partially or completely conceals the surface
of the product. By way of example, figure 1 shows a picture of a billet with scale
on the surface thereof. Specifically, for tracking systems that use markings or paint
and character, barcode or data matrix readers, the scale can make the tracking information
illegible. Removing this residue sometimes requires procedures that are more expensive
than merely carrying out a control of the same, and can alter the metallurgical properties
of the material.
[0003] Spanish patent
ES2378602B1 describes a device for capturing and processing images for profiles of revolution
of hot surfaces which uses light sources that emit light at a different wavelength
than the light emitted by the surface being inspected. Specifically, it proposes using
wavelengths in the green (532 nm), blue (473 nm) or violet (405 nm) spectra. The device
uses three systems, each one made up of at least two linear light sources and a linear
CCD camera. The three systems must be situated on planes that form an angle with respect
to the normal of the surface being inspected and must be distributed in a circumference
at 120º from one another. Thus, linear inspection of tubes or other hot revolution
surfaces (700 - 1000 ºC) is enabled without the emission of the steel itself interfering
with the image quality, which is not possible with conventional cameras. However,
it has been observed that although this device is useful for classifying defects in
pieces and for reading tracking elements, the device is not able to interpret characters
printed on the surface or defects if they are concealed by residues.
[0004] In recent years new technologies have been developed based on terahertz radiation
(THz), also known as sub-millimeter radiation, which refers to electromagnetic radiations
with frequencies between the high frequency end of the microwave band (300 gigahertz
= 300 GHz = 3x10
11 Hz) and the long wavelength end of far infrared light (3000 GHz). In these wavelengths,
this range corresponds to 0.1 mm in infrared and up to 1.00 mm in microwaves. The
terahertz waves are at the farthest end from the infrared band, just before the beginning
of the microwave band. They are considered safe radiation since they are not ionizing.
[0005] Technologies based on terahertz radiation are being used to develop new techniques
for inspecting surfaces and detecting defects in the same. For example, Japanese patent
application
JP2013228329A relates to a device and method for surface inspection based on the emission of waves
in the THz band and on the detection of the intensity distribution of the THz wave
that is reflected off the surface being inspected. A device detects defects on the
surface based on said intensity distribution of the THz wave. However, as in the case
of
ES2378602B1, the device and method are not designed to read the characters printed on the surface
and concealed by residues, but rather to see differences in the reflection off the
background.
[0007] However, the aforementioned proposal was designed for reading ink on paper sheets,
and therefore the objective thereof is to penetrate layers of dielectric material
that have printed elements. Therefore, this proposal does not allow for a direct application
thereof for detecting characters that have been painted on a metal background and
which are concealed by a material such as scale in extreme inspection conditions (high
heat, dirt, a moving element to be inspected, etc.).
[0008] Therefore, it is necessary to develop a detection and reading method for hot-printed
characters on iron and steel products and covered by residues, such as scales, which
allows for these characters to be interpreted both in hot and cold temperatures.
DESCRIPTION OF THE INVENTION
[0009] The present invention provides a method for detecting elements or marks, such as
letters, symbols, codes or identification characters, created for the subsequent identification
of the iron or steel product, completely or partially concealed by undesirable elements,
such as scale, grease, stains, etc. The method is based on the emission of a source
of radiation in the terahertz band that penetrates (passes through) the layer of undesirable
material (dielectric material) that conceals the mark, and on the detection of the
differences in the reflection between the paint (semi-dielectric material) and the
metal background (iron or steel product formed by a conductor material). This way,
the information reflected off the concealed layer is detected, that is to say, the
mark traced on the surface of the product. The marks that are intentionally created
can be traced with paint, including paints designed to be able to be used in high
temperatures.
[0010] In a first aspect of the invention, a method for detecting an element traced on a
surface of an iron or steel product by means of applying a paint is provided, wherein
said element has been covered, at least partially, by a residue that prevents a human
reading, or a reading by conventional artificial vision of said element. The method
comprises: applying a radiation in the terahertz band to said surface of an iron or
steel product that has an element traced with paint concealed behind a residue, wherein
said radiation is emitted by at least one source of radiation in the terahertz band,
such that said radiation penetrates passes through) said residue; detecting a radiation
in the terahertz band reflected by the surface of said iron or steel product covered
by said residue, wherein said reflected radiation is detected by at least one terahertz
radiation detector, obtaining at least one signal reflected off said surface of an
iron or steel product and at least one signal reflected off said traced element on
said surface; processing said reflected signals, analyzing the differences between
said at least one signal reflected off said surface of an iron or steel product and
said at least one signal reflected off said element traced on said surface, such that
the element traced on said surface and covered at least partially by a residue is
reconstructed.
[0011] In embodiments of the invention, at least one detector of said one or more detectors
is arranged normal to the surface of said iron or steel product and at least one source
of said one or more sources is arranged forming an angle between 5º and 30º in relation
to said normal to the surface of said iron or steel product.
[0012] In embodiments of the invention, the element is traced on the iron or steel product
while hot. In these embodiments, the source or sources and the detector or detectors
are preferably protected by thermal protection means.
[0013] In embodiments of the invention, the iron or steel product is a piece of steel.
[0014] In embodiments of the invention, the element is one or more characters, symbols,
codes or drawings.
[0015] In embodiments of the invention, the residue comprises carbon oxide.
[0016] In embodiments of the invention, the processing comprises applying enhancement filters
and character recognition techniques.
[0017] In embodiments of the invention, the paint with which the element is traced on the
surface of an iron or steel product is a paint doped with at least one dopant that
does not change the visible properties or the operation of said paint, but does change
its level of absorption, transmission and reflection in the terahertz band with respect
to the respective levels of absorption, transmission and reflection in the terahertz
band of the surface of the iron or steel product and those of said residue. In embodiments
of the invention at least one dopant is metal. The metal dopant preferably comprises
iron.
[0018] In embodiments of the invention, an identification method for iron and steel products
is provided that comprises: tracing an identification element by means of applying
a paint on a surface of an iron or steel product; and detecting said identification
element once it has been covered at least partially by a residue, by means of applying
the previously described method.
[0019] In a second aspect of the invention, a system for detecting an element traced on
a surface of an iron or steel product by means of applying a paint is provided, wherein
said element has been covered, at least partially, by a residue. The system comprises:
at least a source of radiation in the terahertz band configured to apply a radiation
in the terahertz band to said surface of an iron or steel product that has an element
traced with paint that is concealed behind a residue; at least a terahertz radiation
detector configured to detect radiation in the terahertz band reflected by said surface
of an iron or steel product covered by said residue, obtaining at least one signal
reflected off said surface of an iron or steel product and at least one signal reflected
off said traced element on said surface; means for processing said reflected signals,
analyzing the differences between said at least one signal reflected off said surface
of an iron or steel product and said at least one signal reflected off said element
traced on said surface, and applying enhancement filters and character recognition
techniques, such that the element traced on said surface is reconstructed.
[0020] In embodiments of the invention, at least one detector of said one or more detectors
is arranged normal to the surface of said iron or steel product and at least one source
of said one or more sources is arranged forming an angle between 5º and 30º with respect
to said normal to the surface of said iron or steel product.
[0021] In embodiments of the invention, the system further comprises thermal protection
means to protect at least one source of said one or more sources and at least one
detector of said one or more detectors.
[0022] In embodiments of the invention, the system further comprises one lens arranged in
front of at least one of said one or more detectors.
[0023] In embodiments of the invention, the system further comprises optical conditioning
units in front of at least one source of said one or more sources.
[0024] In embodiments of the invention, the paint with which said element is traced on the
surface of an iron or steel product is a paint doped with at least one dopant that
does not change the visible properties or the operation of said paint, but which does
change its level of absorption, transmission and reflection in the terahertz band
with respect to the respective levels of absorption, transmission and reflection in
the terahertz band of the surface of the iron or steel product and those of said residue.
In embodiments of the invention at least one dopant is metal. The metal dopant preferably
comprises iron.
[0025] In a third aspect of the invention, a computer program is provided that comprises
computer program code instructions to carry out the previously described method.
[0026] The marks intentionally created can also be traced as marks created by impact or
percussion, or by a laser. The method also allows for the detection of undesirable
marks, which are the result of a specific process (cracks, marks from rolling, etc.).
[0027] In a second aspect of the invention, a system for carrying out the aforementioned
method is provided.
[0028] In a third aspect of the invention, a computer program is provided that comprises
computer program code instructions to carry out the previously described method.
[0029] Further advantages and characteristics of the invention will become apparent from
the detailed description which follows and will be specifically indicated in the attached
claims.
BRIEF DESCRIPTION OF THE FIGURES
[0030] As a complement to the description, and for the purpose of helping to make the characteristics
of the invention more readily understandable, in accordance with a practical embodiment
thereof, said description is accompanied by a set of figures constituting an integral
part thereof, which by way of illustration and not limitation represent the following:
Figure 1 shows an example of a piece with scale on the surface thereof. Specifically
it is a billet with scale on the surface thereof.
Figure 2 shows a diagram of the implementation of the method according to a possible
embodiment of the invention.
Figures 3A-3C show an example of the detection process according to a possible embodiment
of the invention.
DESCRIPTION OF AN EMBODIMENT OF THE INVENTION
[0031] Figure 2 shows a diagram of the execution of the method according to a possible embodiment
of the invention by means of a system according to a possible embodiment of the invention.
An iron or steel product 1 is schematically shown, on which one or more marks 2 are
traced in hot temperatures. Figure 2 shows two marks by way of example. The iron or
steel product 1 is, for example, a piece of steel obtained by means of a steelmaking
process. Non-limiting examples of materials from which iron and steel products are
produced are: iron, carbon and different alloys and ferrum. Throughout this text,
the expressions "hot" or "high temperatures" refer to surface temperatures of the
product being treated (in this case, the product 1) greater than 500 ºC, typically
in the range of 900 ºC-1200 ºC, immediately after coming out of the furnace or immediately
after being rolled. The marks 2 are preferably characters, symbols or optical codes
(such as a data matrix or a barcode) made with paint. Although a single iron or steel
product 1 is shown in figure 2, the marks 2 are usually traced, painted or printed
in series as the iron and steel products 1 are being produced and moving along a production
line.
[0032] The marks 2 of figure 2 are preferably made with special paint that can withstand
high temperatures (according to the prior definition). This paint can be doped, as
will be explained further on. After the marks 2 are painted on the surface of the
piece (iron or steel product 1) it is common for residue 3 created by oxidation to
adhere to, or be embedded in or deposited on, said surface, such as scale, swarf or
stains, for example of grease or other residues of the systems, which are formed after
the marks 2 are printed. These residues 3 partially or completely conceal the mark
2 traced on the surface of the product 1. In other words, the residues 3 prevent a
reading by a human or conventional artificial vision of these marks 2. In the iron
and steel industry, these residues 3 usually have an iron oxide content greater than
95 %, and other metals and traces of grease in smaller quantities that make these
residues non-conductive due to the electronic location in the metal center which prevents
the formation of conduction bands. These residues 3 can also be carbon oxide. This
causes that, to a greater or lesser degree, these residues are transparent to the
terahertz band, since the energy on the THZ band is much less than the width of the
atomic electron transition in non-metal compounds, and therefore the incoming photons
of energy in the THZ band can penetrate the non-metal compounds without being absorbed
(just as vissible light passes through glass). By contrast, the energy in the THZ
band does not penetrate metals or water due to the fact that the electronic structure
is more compact in these compounds, with less space between the orbits of the electrons,
as a consequence of which the incoming photons of energy in the THZ band are absorbed
by the medium. To sum up, a detector that works in the terahertz band can detect what
is behind these residues, which are transparent to the terahertz band.
[0033] The method proposed makes it possible to read the marks 2 hidden behind the residues
3, both in cold and hot temperatures, in the conditions of the process on the manufacturing
line. It must be noted that typical manufacturing lines comprise furnaces at very
high temperatures (up to 1200 ºC) and rolling (subjecting the hot or cold steel to
pressure and other processes that generate powder, vapor, etc.). Therefore, one or
more linear terahertz radiation detectors 5 are arranged. Preferably, the linear detector
or detectors 5 are situated in an arrangement normal to the surface being inspected,
meaning to the product 1 marked with marks 2 covered by residues 3. The distance between
the surface of the product 1 being inspected and the detector 5 is preferably between
1 and 2 m, as a means of protection in hot systems. Placed between the detector (or
detectors) 5 and the surface of the product 1 being inspected is a lens 6, also preferably
in an arrangement normal to the surface being inspected, to concentrate the energy
in the sensor (detector) 5. Moreover, one or more sources 4 of radiation in the terahertz
band 4 is arranged. In one possible embodiment, the one or more sources 4 emit in
the band between 300 and 1000 GHz. In other embodiments, other bands within the terahertz
band may be used. The source or sources 4 are preferably situated in an arrangement
between 5º and 30º with respect to the detection zone of the sensor (detector 5),
in other words, with respect to the normal to the surface being inspected. Depending
on the characteristics of the surface of the product 1 being inspected, said angle
is adjusted within the aforementioned range (5 - 30º). Moreover, optical conditioning
units 7 are arranged in front of the source or sources 4, as schematically shown in
figure 2, such that the radiation emitted by these sources 4 is oriented in the most
efficient way towards the line of inspection by these units 7. The radiation emitted
by the source or sources 4 must be strong enough to penetrate (pass through) the material
layer of the undesirable material 3 concealing the mark 2, both in the send 9 and
return 10 of the signal (it must be noted that transparency implies attenuation).
Lastly, when the detection is done in hot (high temperatures), arranged between the
measuring and conditioning units 4, 5, 6, 7 and the product being inspected are thermal
protection means 8 for protecting the units 4, 5, 6, 7 during inspection in high temperatures.
In a possible embodiment, the thermal protection means 8 include equipment or devices
that comprise fiber insulation, a water chamber and/or air conditioning of the clean
area. In another possible embodiment, the thermal protection means 8 comprise overpressure
systems on the optical surfaces to prevent heat and the concentration of water vapor
(not transparent to THZ) as well as the build up of residues. These thermal protection
means 8 are not necessary for cold detection. Figure 2 shows the radiation emitted
9 by the source or sources 4 (the arrow pointing at the product 1) and the radiation
reflected 10 by the surface of the product 1 and by the marks traced with paint, captured
by the detector 5 (arrow pointing towards the detector 5). As a person skilled in
the art will understand, the number of emitting sources 4 and detectors 5, as well
as the arrangement thereof, can vary as a function of the amount of surface of the
product 1 that has a printed mark, drawing, character or set of characters and of
the amount of surface of said product 1 covered by a residue 3, among other factors.
[0034] In embodiments of the invention, the paint used to trace the marks 2 is a commercial
paint for conventional heat tracing. A non-limiting example of convention paint that
can be used is the industrial paint "Paint Slab Marker", by Tebulo. For a correct
detection, it is necessary that the radiation 10 in the terahertz band reflected by
the paint be opaque to the terahertz band, but different from that which is emitted
by the material of which the product 1 is made and on which the marks 2 are printed.
The inventors have observed that, for a correct detection by means of terahertz detectors,
it is necessary for the paint to have a level of absorption, transmission and reflection
of terahertz waves that is different with respect to said levels of the material of
the surface of the product 1 on which the marks 2 are painted. Therefore, the paint
which is used to trace the marks 2 is preferably doped with a dopant (or mixture of
dopants) that does not change the visible properties or the operation of said paint,
but which does change its level of absorption, transmission and reflection in the
terahertz band with respect to said levels of absorption of the material of the surface
of the product 1 and of the material of the residues 3 that are usually deposited
on said surface. In other words, the paint is doped to adjust (modulate) its transparency
and increase the contrast with respect to the background. In embodiments of the invention,
in which the product 1 (for example, a billet as shown in figure 1) is metal (steel,
for example) or comprises metal elements, the inventors have observed that by doping
the commercial paint used to trace the marks 2 with metal elements, the radiation
10 in the terahertz band reflected by the paint is different than the radiation emitted
by the product 1 being analyzed, and at the same time said radiation 10 is opaque
in the terahertz band (that is to say, detectable by the detector 5). In other words,
the paint must be opaque, but not as opaque as the background wall (the surface of
the product 1 being inspected) to be able to differentiate the radiation emitted by
the paint with respect to the radiation emitted by the non-marked surface of the product
1. In a possible embodiment, the paint is doped with metal elements or compounds to
adjust (modulate) the transparency of the same. In particular, the dopant can be a
metal dopant that comprises iron. This way the differences of the reflection between
the paint 2 and the metal background 1, of an incoming radiation 9 at frequencies
in the terahertz band, which penetrates the undesirable material layer 3 that hides
the mark 2 are detected.
[0035] Thus, by applying a radiation 9 in the terahertz band on the surface of the iron
or steel product 1 that has an element (mark, character, etc.) 2 traced with paint
and hidden behind a residue 3, this applied radiation 9 penetrates the residue 3.
The at least one terahertz radiation detector 5 detects the radiation in the terahertz
band reflected 10 by the surface of the iron or steel product 1 covered by the residue
3. At least one signal reflected off the surface of the product 1 and at least one
signal reflected off the element 2 traced on the surface of the product 1 are thus
obtained. These at least two reflected signals are processed, analyzing the differences
between the at least one signal reflected off the surface of the product 1 and the
at least one signal reflected off the element 2 traced on that surface.
[0036] The element 2 traced on the surface and covered at least partially by a residue 3
is thereby reconstructed. After the detection by the detector 5 (or detectors) that
works in the terahertz band, software processing is applied to the signal obtained.
In embodiments of the invention, enhancement filters and character recognition and
classification techniques are applied to the signal, such as deep learning techniques
in order to improve the recognition rate of the characters based on the quality of
the image obtained.
[0037] The detection method is able to identify marks 2 traced on products 1 which are partially
or completely hidden by residues 3 on the production line, that is to say, as the
marked products pass through the production line at the processing speed, typically
up to 10 m/s. Detection can be done both cold and hot. For hot detection, in addition
to protecting the equipment, the attenuation factor introduced through water vapor
present often at high temperatures must be taken into consideration.
[0038] Figures 3A-3C show an example of the detection process. Figure 3A shows the surface
of an iron or steel billet on which a mark formed by the characters "THZ" has been
printed or drawn with hot paint doped with metal powder. Figure 3B shows the previous
surface, on which a layer of residue has accumulated (scale, for example), partially
hiding the characters shown in figure 3A. Lastly, figure 3C shows the result of the
detection and processing carried out by executing the method of the invention. It
may be observed how the hidden characters are detected by the detector 5.
[0039] The method herein described has a special application in the iron and steel industry,
in which painted marks are applied, normally in hot temperatures, and which are read
in both hot and cold temperatures, on pieces that are recently produced, marks that
are usually partially or completely concealed due to the build up of residue, stains,
etc. The method also has an application for the detection of marks created by impact,
tearing or micro percussion, as well as by a marking laser. Likewise, the method also
allows for the detection of undesirable marks, which are the result of a specific
process (cracks, marks from rolling, etc.).
[0040] As can be seen, the proposal of Redo-Sanchez A. et al is not applicable to the detection
and reading of characters printed on iron or steel products, since in these products
a dielectric material layer (residue deposited over the mark) must be penetrated,
and differences in reflection between an opaque background (the iron or steel product,
typically a conductor) and printed elements on said product (the paint, which can
be considered semi-dielectric with respect to the iron and steel product) must be
seen. By contrast, Redo-Sánchez penetrates dielectric material layers that have printed
elements.
[0041] In this text, the word "comprises" and its variants (such as "comprising", etc.)
should not be understood in an exclusive sense, i.e. they do not exclude the possibility
of that which is described including other elements, steps, etc.
[0042] Also, the invention is not limited to the specific embodiments described herein,
but rather encompasses the variations that one skilled in the art could make (e.g.
in terms of choice of materials, dimensions, components, design, etc.), within the
scope of what may be deduced from the claims.
1. - A method for detecting an element (2) traced on a surface of an iron or steel product
(1) by means of applying a paint, wherein said element (2) has been covered at least
partially by a residue (3) that prevents a human reading or a reading by conventional
artificial vision of said element (2),
characterized by:
applying a radiation (9) in the terahertz band to said surface of an iron or steel
product (1) that has an element (2) traced with paint hidden behind a residue (3),
wherein said radiation (9) is emitted by at least one source (4) of radiation in the
terahertz band, such that said radiation (9) passes through said residue (3);
detecting a radiation on the terahertz band reflected (10) by the surface of said
iron or steel product (1) covered by said residue (3), wherein said reflected radiation
(10) is detected by the at least one terahertz radiation detector (5), thereby obtaining
at least one signal reflected off said surface of an iron or steel product (1) and
at least one signal reflected off said element (2) traced on said surface;
processing said reflected signals, analyzing the differences between the at least
one signal reflected off said surface of an iron or steel product (1) and said at
least one signal reflected off said element (2) traced on said surface, such that
the element (2) traced on said surface and at least partially covered by a residue
(3) is reconstructed.
2. - The method of claim 1, wherein said at least one detector (5) is arranged normal
to the surface of said iron or steel product (1) and said at least one source (4)
is arranged forming an angle between 5º and 30º with respect to said normal to the
surface of said iron or steel product (1).
3. The method of either of the claims 1 or 2, wherein said element (2) is hot traced
on the iron or steel product (1), the method preferably comprising protecting said
at least one source (4) and said at least one detector (5) using thermal protection
means (8).
4. - The method of any of the preceding claims, wherein said element (2) is one or more
characters, symbols, codes or drawings.
5. - The method of any of the preceding claims, wherein said residue (3) comprises carbon
oxide.
6. - The method of any of the preceding claims, wherein said processing comprises applying
enhancement filters and character recognition techniques.
7. - A method for identifying iron and steel products (1),
characterized by:
tracing an identification element (2) by means of applying a paint on a surface of
an iron or steel product (1),
detecting said identification element (2) once it has been at least partially covered
by a residue (3) by applying the method of any of the claims 1 to 7.
8. - A detection system of an element (2) traced on a surface of an iron or steel product
(1) by means of applying a paint, wherein said element (2) has been covered at least
partially by a residue (3),
characterized by:
at least one source (4) of radiation in the terahertz band configured for applying
a radiation (9) in the terahertz band on said surface of an iron or steel product
(1) that has an element (2) traced with paint hidden behind a residue (3);
at least one terahertz radiation detector (5) configured for detecting a radiation
in the terahertz band reflected (10) by said surface of an iron or steel product (1)
covered by said residue (3), thereby obtaining at least one signal reflected off said
surface of an iron or steel product (1) and at least one signal reflected off said
element (2) traced on said surface;
means for processing said reflected signals, analyzing the differences between the
at least one signal reflected off said surface of an iron or steel product (1) and
said at least one signal reflected off said element (2) traced on said surface, and
applying enhancement filters and character recognition techniques such that the element
(2) traced on said surface is reconstructed.
9. - The system of claim 8, wherein said at least one detector (5) is arranged normal
to the surface of said iron or steel product (1), and said at least one source (4)
is arranged forming an angle between 5º and 30º with respect to said normal to the
surface of said iron or steel product (1).
10. - The system of any of the claims 8 or 9, which further comprises thermal protection
means (8) for protecting said at least one source (4) and said at least one detector
(5).
11. - The system of any of the claims 8 to 10, which further comprises a lens (6) arranged
in front of said at least one detector (5).
12. - The system of any of the claims 8 to 11, which further comprises optical conditioning
units (7) in front of the at least one source (4).
13. - The method of any of claims1-6 or the system of any of the claims 8 to 12, wherein
said paint with which said element (2) is traced on the surface of an iron or steel
product (1) is a paint doped with at least one dopant that does not change the visible
properties or the operation of said paint, but which does change its level of absorption,
transmission and reflection in the terahertz band with respect to the respective levels
of absorption, transmission and reflection in the terahertz band of the surface of
the iron or steel product (1) and those of said residue (3).
14. - The method or system of claim 13, wherein said at least one dopant is metallic,
said at least one metallic dopant preferably comprising iron.
15. - A computer program that comprises computer program code instructions for carrying
out the method according to any of the claims 1 to 7.